Sole comprising individually deflectable reinforcing members, shoe with such a sole, and method for the manufacture of such items
11779077 · 2023-10-10
Assignee
Inventors
- Robbie PATERSON (Nuremberg, DE)
- Harry Miles (Nuremberg, DE)
- Daniel Ruiz (Erlangen, DE)
- Fabian Schweizer (Nuremberg, DE)
- Sam FORESTER (Nuremberg, DE)
- Falk BRUNS (Nuremberg, DE)
- Peter Valdivia (Nuremberg, DE)
- Jochen BARTL (Langensendelbach, DE)
- Tobias Biegel (Großhabersdorf, DE)
- Valentin PERRIN (Nuremberg, DE)
- Jürgen Weidl (Aurachtal, DE)
- Matthias Schmitt (Nuremberg, DE)
- Heiko Schlarb (Neustadt an der Aisch, DE)
- Alejandro Alcaniz (Nuremberg, DE)
- Ronny Herman Gerard Groeneveld (Vreden, DE)
Cpc classification
A43B13/181
HUMAN NECESSITIES
B29D35/0009
PERFORMING OPERATIONS; TRANSPORTING
International classification
A43B7/1445
HUMAN NECESSITIES
Abstract
A sole for a shoe, the sole comprising reinforcing members extending in a front half of the sole, wherein at least a first one of the reinforcing members further extends rearwardly beyond a midfoot area and into a heel area of the sole and wraps up to a posterior portion of an ankle region. A shoe, in particular a running shoe, comprising such a sole. A method for the manufacture of such items.
Claims
1. A sole for a shoe, the sole comprising: a midsole; a reinforcing structure that comprises reinforcing members at least partially embedded in the midsole within a front half of the sole, wherein: a first one of the reinforcing members extends rearwardly beyond a midfoot area of the midsole and into a heel area of the midsole and forms a first section of the reinforcing structure behind the midfoot area; a second one of the reinforcing members extends rearwardly beyond the midfoot area and into the heel area and forms a second section of the reinforcing structure behind the midfoot area; and the first section and the second section wrap upward behind the heel area, and merge into each other behind the heel area.
2. The sole according to claim 1, wherein the reinforcing members are configured to be independently deflected by forces acting on the sole during a gait cycle.
3. The sole according to claim 1, wherein the first reinforcing member is a medial reinforcing member and the second reinforcing member is a lateral reinforcing member.
4. The sole according to claim 1, wherein the first reinforcing member further comprises a flattened tip extending into a region underneath the first metatarsophalangeal head.
5. The sole according to claim 1, wherein the reinforcing members are rods or tube-shaped members.
6. The sole according to claim 1, wherein a diameter of the reinforcing members varies.
7. The sole according to claim 1, wherein at least some of the reinforcing members comprise hollow sections, and wherein a wall thickness of the hollow sections varies.
8. The sole according to claim 1, wherein there are five reinforcing members, each corresponding to a respective metatarsal bone.
9. The sole according to claim 8, wherein the reinforcing members corresponding to the first and the third metatarsal bone have a higher deflection stiffness than the three remaining reinforcing members.
10. The sole according to claim 8, wherein the reinforcing members corresponding to the first and the third metatarsal bone have a larger diameter or larger wall thickness than the three remaining reinforcing members.
11. A shoe comprising a sole according to claim 1.
12. The sole according to claim 1, wherein the first section and second section are at least partially embedded in the midfoot area and extend out of the midsole behind the heel area.
13. The sole according to claim 1, wherein a third one of the reinforcing members is connected to the second one of the reinforcing members by a connection region of the reinforcing structure located in the midfoot area of the sole.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1) Possible embodiments of the present disclosure are described in more detail below with reference to the following figures:
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DETAILED DESCRIPTION
(47) Possible embodiments of the different aspects of the present disclosure are described below, predominately with respect to running shoes. It is, however, emphasized once again that the different aspects of the present disclosure may also be practiced in different kinds of shoes and are not limited to the specific embodiments set forth below.
(48) Reference is further made to the fact that in the following paragraphs, various embodiments of the present disclosure are described in more detail. A person of ordinary skill in the art will understand, however, that the features and possible modifications described with reference to these specific embodiments may also be further modified and/or combined with one another in a different manner or in different sub-combinations, without departing from the scope of the present disclosure. Individual features or sub-features may also be omitted, if they are dispensable to obtain the desired result. In order to avoid redundancies, reference is therefore made to the explanations in the preceding sections, which also apply to the following detailed description.
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(51) The sole 100 may be used in a sports shoe, in particular in a running shoe.
(52) The upper and lower midsole parts 111, 112 may comprise or be made of a plastic foam material. The upper and lower midsole parts 111, 112 can comprise or be made of the same material, or they can comprise or be made of different materials. It is also possible that within a given midsole part, the material composition changes locally, i.e., that different materials are used in different regions, e.g., to locally influence the mechanical properties of the upper and/or lower midsole part 111, 112. The plastic foam material can comprise a homogeneous foam material, like ethylene-vinyl-acetate (EVA) or injection-molded thermoplastic polyurethane (TPU), or thermoplastic polyester ether elastomer (TPEE), or other suitable materials. The plastic foam material can also comprise a particle foam. For example, particle foams made of or comprising particles of expanded thermoplastic polyurethane (eTPU), expanded polyamide (ePA), expanded polyether-block-amide (ePEBA) and/or expanded thermoplastic polyester ether elastomer (eTPEE) are particularly well suited for use in performance footwear, because they provide a high degree of cushioning and energy return back to the wearer. For example, particle foams of eTPU maintain their beneficial properties over a large temperature range (e.g., from −20° C. up to 40° C.). Particle foams including particles of expanded polylactide (ePLA), expanded polyethylene terephthalate (ePET), expanded thermoplastic olefin (eTPO) and/or expanded polybutylene terephthalate (ePBT) are also possible. To give one specific example, the lower midsole part 112 may be made from a homogeneous EVA- or TPU- or TPEE-foam material, to provide good overall stability and wear resistance to the sole 100, while the upper midsole part 111 may be made from a particle foam comprising particles of eTPU, ePA, ePEBA, eTPEE, or any combination thereof, to provide good cushioning, high energy return, and a smoother transition which reduce eccentric forces and give a comfortable ride.
(53) It is emphasized, however, that alternatively or in addition to using a foam material for the midsole 110, other materials and manufacturing options may also be used. For example, the midsole 110 or parts thereof may comprise or be comprised of a lattice structure, for example an additively manufactured lattice structure (e.g., a structure made using a 3D printing method or a laser sintering method or a stereolithography method), which, as already mentioned above, may be useful both for long distance running shoes, where a high cushioning is preferred, and for sprint spikes or lower distance running shoes where high cushioning is not a necessity, but high stiffness and anatomical guidance of the foot during ground contact is beneficial.
(54) Moreover, it is also emphasized that the present disclosure also covers embodiments wherein the sole does not comprise separate upper- and lower midsole parts, but only one unified midsole component. Such a midsole may also comprise or be made of one or more of the above-mentioned homogeneous foam materials and/or particle foams and/or non-foamed materials like a lattice structure as mentioned above, for example.
(55) The load distribution member 140 is located in the back half of the sole 100, predominately in the heel area of the sole 100, where heel strike occurs. It also extends some distance towards the center of the sole 100, e.g. the midfoot area, such that in a vertical projection of the sole 100 the load distribution member 140 overlaps partly with the reinforcing structure 120 provided by the five reinforcing members 121-125 (more details on this below). The load distribution member 140 is provided as a substantially planar load distribution plate in the embodiment shown here, but other geometries like a slight bowl-shape or cup-shape, potentially including a heel counter, are also possible. To save weight but still provide the desired degree of load distribution, the load distribution member 140 may, for example, comprise or be made of carbon fibers, a carbon fiber composite material, and/or a glass fiber composite material, such as, for instance, a polyamide material infused with carbon fibers and/or a polyamide material infused with glass fibers.
(56) Turning to the exemplary embodiment of the reinforcing structure 120 provided by the five reinforcing members 121-125, the reinforcing members 121-125 extend in the front half of the sole 100. More specifically, the reinforcing members 121-125 extend from the midfoot area—here the area under the arch of the foot—up to the toes. The reinforcing members 121-125 extend substantially longitudinally through the sole 100, i.e. their longitudinal (i.e., from the back of the sole 100 to the front) extension is much larger than their lateral and medial extension along their course through the sole 100. The reinforcing members 121-125 are further arranged next to each other in the medial-to-lateral direction, starting with the reinforcing member 121 on the medial side of the sole 100 and continuing up to the reinforcing member 125 on the lateral side of the sole 100. The reinforcing members 121-125 of the embodiment shown here are of circular cross-section, and their central symmetry axis defines what is called their “flow-lines” in the present document. Other cross-sectional shapes are, however, also covered by the present disclosure. Examples of further possible cross-sectional shapes include elliptic, prismatic, trapezoid, quadratic, or rectangular cross-sections.
(57) As mentioned above, the reinforcing members 121-125 are positioned between the upper and lower midsole part 111, 112 and may be completely embedded within the midsole 110. If necessary or deemed beneficial, the reinforcing members 121-125 may be connected to the material of the midsole 110 by a bonding agent or glue, for example, or by some mechanical fastening means. However, since they are completely embedded within the material of the midsole 110, this may not be necessary. In other embodiments, the reinforcing members 121-125 may also partly protrude from the midsole material and be exposed on the outside of the sole 100, for example at the medial or lateral sidewall. It is, however, generally preferable that the reinforcing members 121-125 are not exposed on the top side and the bottom side of the sole 100, to not impair the wearing sensation and traction of the sole, respectively.
(58) The reinforcing members 121-125 are configured to move independently from each other under the forces acting during a gait cycle. In particular, the reinforcing members 121-125 are configured to be deflected independently from one another by the forces acting during a gait cycle, and hence provide a locally fine-tuned support and reinforcing function that cannot be achieved by a simple unitary structure known from the art, for example. The reinforcing members 121-125 thus cater to the complicated anatomy of the human foot and the complex movement patterns involved in running or sprinting motions, by allowing different regions of the sole 100, in particular in the front half and the toe region of the sole 100, to be supported and reinforced to different degrees. This provides a more biomechanically-driven solution than are known from the art. The reinforcing members 121-125 help to provide a smoother landing of the foot and a smooth transition, thereby reducing the eccentric forces and reducing overloading of muscle, bones, and joints. This helps to lower the overall risk of injuries during sports.
(59) The reinforcing members 121-125 are non-linear, i.e. their flow-lines do not follow a straight line, in order to further cater to the human anatomy. In the embodiment shown here, the reinforcing members 121-125 do not even comprise straight sections, although this is generally possible within the scope of the present disclosure. As can best be seen in the medial side views of
(60) Put into more mathematical language, the shape (e.g., as defined by the flow-line) of each of the reinforcing members 121-125 comprises a minimum or localized low point with regard to the horizontal plane. It is noted that this statement includes the assumption that the sole sits on a horizontal, flat piece of ground (if the sole is tilted, then the reference-plane must also be tilted in the same manner) and in a force-free state (i.e., without being bent or twisted). The position of these low points is indicated in
(61) As mentioned above, the reinforcing members 121-125 form a concave structure e.g., a structure in the shape of a bowl or saucer) in the region between the midfoot area and the toes. With regard to the low points 131-135 this means that these points sit a certain distance below the plane tangential to the upper side of the reinforcing structure 120 that is formed by the reinforcing members 121-125. A clear illustration of this concept is given by
(62) To cater for the typical human anatomy, all of the low points 131-135 may be a distance of at least 5 mm below the above-defined tangential reference-plane, or even a distance of at least 8 mm. As mentioned above, the depth can also be adjusted according to the intended activity for which the sole and shoe are provided. For example, for an activity that requires or favors more stability, a larger depth may be chosen. However, as also already mentioned, if, e.g., a particularly thin midsole is wanted, then the depth can also be chosen smaller.
(63) Alternatively or in addition to following a lower limit on the depth of the structure defined by the reinforcing members 121-125, the distance of the low points 131-135 to the mentioned tangential reference-plane may also be adjusted or changed depending on the position of the respective low point with regard to the medial-to-lateral direction. For example, the center point 133 may be the deepest, and then the distance to the reference-plane (i.e., the depth of the low points) decreases towards the lateral and medial edges, following the general anatomy of the human foot. Other configurations are, however, also possible, to take account of a specific anatomical feature or some individual movement pattern, for example.
(64) The reinforcing members 121-125 can be solid (i.e., rod-shaped members) or they can be hollow (i.e., tube-shaped members), or they can be partly solid and partly hollow, depending on the desired trade-off between factors like weight, stability, stiffness, etc. Not all of the reinforcing members 121-125 have to be of the same construction in this regard.
(65) As can be seen in the vertical projection (or top view) of some of the components the sole 100 shown in
(66) As can also be clearly seen in
(67) Alternatively or in addition to having different diameters, the reinforcing members 121 and 123 could also have a larger wall thickness than the reinforcing members 122, 124, and 125, if they are provided tube-like or at least have hollow sections.
(68) The reinforcing member 121 furthermore has an extended front section 126 which preferably curves in under the tip of the big toe, to provide even better support in this region. One reason for this specific shape and design of the reinforcing members 121 and 123 is that an increased stiffness for the first metatarsal is beneficial as this is typically the largest and strongest structure of the five metatarsals in the foot, which hence has to exert and withstand the highest forces during running. The third metatarsal in the center of the foot, on the other hand, sits naturally around the center of pressure during the stance phase of the gait cycle during running, and hence also benefits from increased support. This further helps the load to get biomechanically driven and evenly distributed between the different MTP bones. This will reduce the risk of injuries.
(69) The different diameters of the reinforcing members 121 and 123 compared to the reinforcing members 122, 124, and 125 is also visible in
(70) More generally speaking, it is mentioned that the diameter and/or wall thickness (for hollow or partly hollow members) of the reinforcing members 121-125 may also be altered and adapted in a different manner between them, and the diameter and/or wall thickness also does not need to stay constant along a given reinforcing member, even if this is the case in the sole 100 shown in
(71) Further examples of shoe soles 900 and 1000a-d with different configurations of rod-shaped or tube-shaped reinforcing members are discussed below in relation to
(72) The reinforcing members 121-125 can comprise or be made of a large number of materials. However, to achieve a beneficial tradeoff between stiffness and reinforcement on the one hand, and low weight on the other hand, preferred materials for the construction of the reinforcing members 121-125 are carbon fibers, carbon fiber composite materials, and/or glass fibers composite materials, such as for instance, polyamide materials infused with carbon fibers and/or polyamide materials infused with glass fibers. Besides their good stiffness-to-weight ratio, they are also very adaptable when it comes to the kinds of geometries and shapes of reinforcing members that can be made out of them, which is of particular importance to obtain a good fit for an object as complex as a human foot. Other possible materials are, for example, metal, wood, or injection-molded plastic materials.
(73) Potential methods for the manufacture of the reinforcing members 121-125 include: molding (e.g. injection molding), additive manufacturing (e.g., 3D printing), or carbon extrusion, for example.
(74) Details pertaining to a method for the manufacture of reinforcing members or structures containing hollow (e.g., tube-shaped) sections are discussed below in relation to
(75) A further feature of the sole 100, which was already briefly touched upon above but which becomes more clearly visible from the top view in
(76) Alternatively or in addition to having such a load distribution member 140, the sole may also comprise a forefoot support plate, as discussed below in relation to
(77) A sole 200 according to some embodiments (shown in
(78) The sole 200 comprises a midsole 210 with an upper midsole part 211 and a lower midsole part 212, between which five reinforcing members 220 are positioned. The reinforcing members 220 are completely embedded within the midsole 210. The reinforcing members 220 are again rod-shaped or tube-shaped, and the reinforcing members corresponding to the first and third metatarsal have a larger diameter than the other three reinforcing members. The sole also comprises a load distribution member 240 arranged predominately in the heel area and on top of the upper midsole part 211, as well as an outsole 260, which in the embodiment shown here comprises several individual sub-parts. However, in some embodiments, the outsole can comprise one unitary piece.
(79) In some embodiments, the lower midsole part 212 comprises five grooves 215, each corresponding to one of the five reinforcing members 220. This may help to secure the reinforcing members 220 in their position and thus help to avoid or limit the use of adhesives or glues, for example, and to generally facilitate assembly of the sole 200.
(80) A sole 300 according to some embodiments (shown in
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(82) The sole 300 comprises a midsole 310 with an upper midsole part 311 and a lower midsole part 312, but now with only four reinforcing members 321-324 positioned between them to form the reinforcing structure 320. This structure is again completely embedded within the midsole 310.
(83) Reducing the number of individual reinforcing members may, for example, simplify the construction and reduce weight and costs. On the other hand, it might give up a certain degree of control over the reinforcing function provided by the reinforcing structure 320, compared to the structure 120 with five individual members 121-125, for example. On the other hand, it may well be found that for a specific activity, support of the fifth metatarsal and fifth toe may not be necessary, and then one reinforcing member may simply be omitted with the remaining four reinforcing members 321-324 still corresponding to the first to fourth metatarsal. Or the most lateral of the four reinforcing members, i.e. reinforcing member 324, may be associated with supporting both the fourth and fifth metatarsal, while the first three reinforcing members 321-323 correspond to one metatarsal each. Further permutations in this regard are conceivable for a person of ordinary skill in the art. The reinforcing members 321-323 are once again rod-shaped or tube-shaped, as shown in
(84) The sole 300 also comprises a load distribution member 340 arranged predominately in the heel area and on top of the upper midsole part 311. The sole also comprises an outsole 360, with several individual sub-parts.
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(87) The sole 400 comprises a midsole 410 with an upper midsole part 411 and a lower midsole part 412. In sole 400 shown in
(88) The sole also comprises a reinforcing structure 420 with four reinforcing members 421-424 to be positioned between the midsole parts 411, 412 and to be completely embedded within the midsole 410.
(89) A particular feature of the reinforcing structure 420 is that the four reinforcing members 421-424 are connected in the midfoot area by a connection member 428, which is provided as small connecting bars between the individual reinforcing members 421-424. This may facilitate assembly of the sole 400 but also manufacturing of four reinforcing members 421-424 themselves, as the individual reinforcing members may be manufactured or molded as a single, (partly) connected unit. The connection member 428 may also increase the stability of the sole 400 in the midfoot area. It is noteworthy that in the front half of the sole, in particular in the forefoot area, there is no connection between the reinforcing members 421-424, to not impede their ability to deflect individually under the forces acting during a gait cycle.
(90) Using a connection member like member 428 may also compensate (at least partly) for not using a load distribution member in the heel area of the sole, as is the case for the sole 400 shown in
(91)
(92) The sole 500 again comprises a midsole 510 with an upper midsole part 511 and a lower midsole part 512, as well as an outsole 560 with several individual pieces. All of what has been said with regard to these components in the context of the soles 100, 200, 300, and 400 also applies here (as far as physically and technically compatible) and is not repeated again.
(93) A difference to the soles 100, 200, 300, and 400 described above lies in the shape and structure of the reinforcing structure 520, which in the case at hand is provided by two plate-like reinforcing members 521 and 522. Even though these two reinforcing members have a different shape than the reinforcing members discussed above, they are still configured to be independently deflected by the forces acting on them during a gait cycle. Despite their plate-like shape, the reinforcing members 521 and 522 may also have a hollow core or hollow sections, for example. They may also be solid members.
(94) Another difference to the embodiments described above is that the reinforcing members 521 and 522 extend rearwardly beyond the midfoot area and into the heel area, up to the calcaneus. This can increase the stiffness of the entire sole, not only the front half.
(95) Further indicated in
(96) What can be seen from the flow-lines is that both reinforcing members 521 and 522 comprise a non-linear section extending across the front half of the sole 500. In the back half of the sole 500, the reinforcing members 521 and 522 comprise straight or at least approximately straight sections. More specifically, in the front half of the sole 500 the reinforcing members 521 and 522 provide a concave shape to the reinforcing structure 520, with both low points 531 and 532 sitting a certain distance below the plane tangential to the upper side of the reinforcing structure 520. Suitable values for a lower boundary on this distance have already been discussed and are not repeated again, because the discussed values may also apply to plate-like reinforcing members like the members 521 and 522.
(97)
(98) The sole 600 once more comprises a midsole 610 with an upper midsole part 611 and a lower midsole part 612, as well as an outsole 660 with several individual parts. These components have already been extensively discussed and all of the above-said also applies here.
(99) In the sole 600, the reinforcing structure 620 is provided by four plate-like reinforcing members 621-624, compared to the two of the sole 500. One specific feature of the sole 600 is that the reinforcing members 621-624 have slightly raised sections 631-634 along their central longitudinal axes (i.e., at least approximately following their flow-lines), starting approximately at the rear end of the foot arch and extending forwardly up to the toe area. For example in the cross-section along the cut-line A-A shown in the bottom left of
(100)
(101) Another option to increase the overall stability of the sole 600 while not unduly impairing the independency of movement of the individual reinforcing members 621-624 is illustrated in
(102)
(103) The soles 700 and 800 are quite similar, for example, to the sole 300 discussed above. Both soles comprise a midsole 710, 810 with an upper midsole part 711, 811 and a lower midsole part 712, 812 as well as an outsole 760, 860, respectively. Both soles 700, 800 also comprise a reinforcing structure 720, 820 with four reinforcing members 721-724 and 821-824, respectively.
(104) Redundancies are therefore avoided by not repeating everything that has been said about the corresponding elements and components above, which also applies to the embodiments 700, 800 at hand.
(105) One difference, though, is the cross-section of the reinforcing members 721-724 and 821-824. These are a hybrid between plate-like and rod-shaped or tube-shaped, and the cross-section also changes along the reinforcing members. While the front and back tips of the reinforcing members 721-724 and 821-824 are flattened out, their middle sections are circular or elliptic in cross-section. Flattening out the tips, in particular towards the front of the sole 700, 800, may be beneficial because the sole typically becomes thinner towards its front end and there is thus less room to accommodate the reinforcing members. Thinning them out towards the front end may thus help to avoid an excessively thick and bulky front half of the sole.
(106) Moreover, the reinforcing members 721-724 and 821-824 also differ in their individual length. Generally, the longer a reinforcing member is, the more transitional support during the stance phase it will provide, as well as a better guidance through the engineered motion. Choosing different lengths for the reinforcing members 721-724 and 821-824 customizes the force distribution along the different metatarsal bones in a more anatomical and ergonomical manner, compared to known unitary structures.
(107) It is explicitly noted at this position that this option of choosing different length for the different reinforcing members also pertains to all other embodiments described in this document (unless explicitly stated otherwise), and is not limited to the specific embodiments 700 and 800 of
(108) The sole 800 also includes a mesh-like material 880, onto which the reinforcing members 821-824 are laminated, or otherwise connected to, to increase the overall stability, facilitate assembly, and/or increase the life-span of the sole 800, for example.
(109)
(110) The soles 900 and 1000a-d shown in
(111) The sole 900 shown in
(112) The reinforcing structure 920, which is again shown in isolated form on the right hand side of
(113) The reinforcing members 921 and 923 corresponding to the first and third toe/metatarsal bone have a larger diameter than the remaining three reinforcing members 922, 924, and 925 to provide additional support by their increased stiffness to the first and third toe/metatarsal bone. If shaped tube-like (e.g. hollow or with hollow sections), the reinforcing members 921 and 923 can alternatively or additionally also have a larger wall thickness than the remaining three reinforcing members 922, 924, and 925.
(114) The five reinforcing members 921-925 extend throughout the front half of the sole 900 and approximately up to the back edge of the arch region, where they are connected by a connecting member 928, which in the case at hand is also provided as a rod-shaped or tube-shaped member. Each of the five reinforcing members 921-925 is connected to the connecting member 928 by a short passage 929 of reduced diameter. This connection at the back edge of the arch region can provide an additional degree of stability to this sensitive region of the foot to help avoid injuries or fatigue of the wearer.
(115) The soles 1000a-d shown in
(116) Each of the reinforcing structure 1020a-d comprises five reinforcing members 1021a-1025a, 1021b-1025b, 1021c-1025c, and 1021d-1025d, respectively, extending throughout the front half of the sole 1000a-d and each corresponding to a respective toe/metatarsal bone of the foot. The reinforcing members 1021a-1025a, 1021b-1025b, 1021c-1025c, and 1021d-1025d also extend beyond the arch region and into the back half of the sole.
(117) A peculiarity of the reinforcing structures 1020a-d is that some, or even all, of the reinforcing members 1021a-1025a, 1021b-1025b, 1021c-1025c and 1021d-1025d are formed from a continuous rod or tube of material (i.e. the reinforcing members are connected to and merge into each other in certain regions of the sole, in particular in the region underneath the rearfoot/heel). Still, at least two of the reinforcing members of each sole 1000a-d are independent from each other in the sense that they may react and deform independently under a pressure load during walking or running, in particular in the front half of the sole (as shown by the reinforcing members 1022b, 1024b, and 1025b in
(118) In the reinforcing structures 1020a, 1020b, and 1020c, the medial, lateral, and central reinforcing members (e.g., the reinforcing members 1021a, 1023a, 1025a and 1021b, 1023b, 1025b and 1021c, 1023c, 1025c) have a larger diameter than the remaining two reinforcing members of the respective structure, and they are provided as hollow tubes, while the thinner two reinforcing members are provided as solid rods. The difference in diameters is shown by the cross sections 10a-c taken in the arch region of each of the depicted soles 1000a-c in
(119) In the reinforcing structure 1020d of
(120) An outsole 1060a-d that may be attached to the midsoles 1010a-d is also schematically shown in
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(123) The reinforcing structure 1120 has five reinforcing members 1121-1125, each corresponding to one toe/metatarsal bone of the foot. The reinforcing member 1121 corresponding to the big toe/first metatarsal bone also curls in underneath the big toe (e.g., the region 1126), to provide additional support for toe-off, as already discussed numerous times. In the exemplary embodiment shown here, all of the reinforcing members 1121-1125 have more or less (e.g. within a few percent, for example within 10%, or 5%, or 2%) the same diameter (understood, e.g., as their diameter at a certain cross-sectional plane or longitudinal position along the sole, or as their average diameter along their extension). In other cases, that may be different, though. Also, if the reinforcing members 1121-1125 are provided tube-shaped (i.e. have at least some hollow sections), their wall thickness may also vary. For example, the wall thickness of the members 1121 and 1123 may be larger, making them stiffer than the remaining members, as already discussed.
(124) In other respects, the reinforcing structure 1120 is similar to, for example, the reinforcing structures 120, 220, or 920, and reference is therefore made to the corresponding statements above, for conciseness.
(125) The forefoot support plate 1190 is arranged beneath the reinforcing structure 1120 in the present embodiment. However, it may in principle also be arranged above it. In the shown examples, the forefoot support plate 1190 also acts as an outsole or part of the outsole in the forefoot region of the sole. The forefoot support plate 1190 may, for example, be made from, or comprise a fiber-reinforced low-weight material to provide increased stiffness for a dynamic and efficient push-off, for example for running or sprinting shoes.
(126) To further facilitate such a dynamic push-off and fast movements, the forefoot support plate 1190 of the shown embodiments comprises both profile elements 1199 to improve traction, as well as grommets or sockets 1198 into which spikes or cleats (not shown in
(127) In
(128) What is not shown in
(129)
(130)
(131) It is once again pointed out that everything that has been said or disclosed so far, in particular with regard to the embodiments and examples of
(132) The sole 1200 comprises a reinforcing structure 1220 containing five reinforcing members 1221-1225 extending in the front half of the sole 1200 and each corresponding to a toe/metatarsal bone of the foot (however, in other embodiments a smaller or larger number of reinforcing members is also possible, e.g. 2, 3, 4, 6, or 7 reinforcing members).
(133) A first medial reinforcing member 1221 corresponds to the big toe/first metatarsal bone. A second lateral reinforcing member 1225 corresponds to the 5.sup.th metatarsal bone. Between these two, three reinforcing members 1222, 1223, and 1224 are arranged, corresponding to the 2.sup.nd, 3.sup.rd, and 4.sup.th metatarsal bone, respectively.
(134) The first medial reinforcing member 1221 comprises a flattened or taper tip that extends towards the front edge/tip of the sole 1200 (as shown in
(135) The reinforcing members 1221 and 1223 corresponding to the 1.sup.st and 3.sup.rd metatarsal bones have a larger diameter than the remaining three reinforcing members 1222, 1224, and 1225. This can be seen from
(136) In the region of the arch of the foot, the reinforcing members 1222-1225 are further connected by a hollow connection region 1228 with a central surface bulge (as shown in the cross-section n-n′ in
(137) It is pointed out that in the center of the hollow connection region 1228, in the area indicated by the ellipse 1299, the dashed lines do not indicate a separate tube-shaped member, but a surface bulge on the hollow connection region 1228 which is slightly higher (6 mm) than the rest of this hollow midfoot connection region 1228 (5 mm) (as shown in the cross section n-n′).
(138) The first medial reinforcing member 1221 and the second lateral reinforcing member 1225 further extend rearwardly beyond the midfoot area and into the heel area of the sole and form sections 1221a and 1225a, respectively, that wrap up to the posterior portion of the ankle region and merge into each other behind the heel in region 1227 (see
(139) To further promote this effect, and while most of the reinforcing members are preferably provided as hollow members, (e.g. tube-shaped as shown by the cross-sections in
(140) Irrespective of the additional support provided by the sections 1221a and 1225a and heel support, where the two are joined in the region 1227, the reinforcing members 1221-1225 are still configured to be independently deflected by forces acting on the sole during a gait cycle in the front half of the sole 1200, so that the corresponding advantages, which have already been discussed in detail, are not lost.
(141) Finally, as already mentioned,
(142)
(143) A further embodiment of a sole 1400 is shown in
(144) The sole 1400 comprises a midsole 1410 with an upper midsole part 1411 and a lower midsole part 1412, between which reinforcing structure 1420 is positioned. It is completely embedded within the midsole 1410. The sole also comprises an outsole 1460, which in the embodiment shown here comprises several individual sub-parts (this need not always be the case, however).
(145) With regard to the different midsole parts 1411, 1412, the outsole 1460, and possible details and materials that may be used in this regard, reference is in particular made to the corresponding statements and explanations given with regard to these components in relation with
(146)
(147) The following discussion will focus on the manufacture of one single hollow section of such a reinforcing structure for clarity of exposition, but a person of ordinary skill in the art will understand that the method may also be expanded to the manufacture of several such hollows section, potentially in combination with solid/non-hollow sections, on a single machine and in a single go. The component obtained by the method may, of course, also be subsequently joined, glued, connected, or secured to other components or parts to for the reinforcing structure if need be. Details about such steps will not be the focus of the following discussion, however.
(148) The method 1500a comprises the step of injecting a liquid molding material into a molding cavity 15 of a mold, the molding cavity 15 having a shape corresponding to the outer dimensions of the reinforcing member with the hollow section that is to be manufactured (for clarity, the case of one hollow reinforcing member being manufactured is discussed here and shown in
(149) The liquid molding material may be a plastic material suitable for injection molding, for example, EVA, TPU, or some other material known to a person of ordinary skill in the art.
(150) The method further comprises (see reference 1520a in
(151) To achieve this displacement of the injected material, during the above two steps. An exit path 20 leading to an outlet well 30 is closed, such that the gas pressure mounts and can be maintained within the molding cavity 15.
(152) Once a sufficient amount of gas has been injected and a sufficient gas pressure been established, the exit path 20 is opened such that the pressurized displacement gas washes out the still liquid material from the center of the molding cavity 15 and into the outlet well 30, (see reference 1530a in
(153)
(154) At reference 1510b, a liquid material is injection molded by an injection molding machine 40 into a molding cavity 15 having a shape corresponding to the outer dimensions of the reinforcing member with the hollow section that is to be manufactured.
(155) At reference 1520b, the method 1500b comprises injecting a displacement gas or liquid (e.g., water) into the molding cavity 15 under pressure. In the present case, this is done via an inlet path 20 that will also be used as exit path to wash out the liquid material from the center of the molding cavity 15. Since the displacement medium is injected via the path 20 into the molding cavity 15 under pressure, the medium itself seals off the path 20 as long as the injection pressure is kept up, and no additional valve or outline line is needed in this case.
(156) This is done at reference 1530b, where the displacement gas or liquid is removed again from the molding cavity 15 via the path 20 and into an outlet well 30 within a corresponding unit 50, taking with it the liquid material still present in the center of the molding cavity 15 at this point in time.
(157) Prior to the removal at reference 1530b, the injected molding material may be allowed to set or cure at least partially within the molding cavity 15, particularly at the walls of the molding cavity 15 (which may be heated for this purpose), while the material in the center is still kept in the liquid phase. This facilitates the removal of the unwanted molding material in the center of the molding cavity along with the removal of the displacement medium (this option also applies to the embodiment 1500a discussed above).
(158) Afterwards, the component may be allowed to set and cure (e.g., while being actively cooled), and then be demolded, see reference 1540b in
(159) In the following, further examples are described to facilitate the understanding of the present disclosure.
(160) In a first example, a sole for a shoe, in particular a running shoe, comprising: reinforcing members extending in a front half of the sole, wherein the reinforcing members are configured to be independently deflected by forces acting on the sole during a gait cycle.
(161) In a second example, the sole according to example 1, wherein each of the reinforcing members comprises a non-linear section.
(162) In a third example, the sole according to example 2, wherein the non-linear sections comprises a section having a concave shape in a side view of the sole.
(163) In a fourth example, the sole according to one of examples 2-3, wherein each of the reinforcing members comprises a localized low point relative to a horizontal plane, and wherein each of the low points is located in the front half of the sole.
(164) In a fifth example, the sole according to example 4, wherein each of the low points is located in a region between a midfoot area and a toe area of the sole.
(165) In a sixth example, the sole according to example 5, wherein each of said low points is located in a region of the metatarsophalangeal joints.
(166) In a seventh example, the sole according to one of examples 4-6, wherein each of the low points is located at a distance of at least 5 mm beneath a plane that is tangential to an upper side of a structure formed by the reinforcing members, preferably at least 8 mm.
(167) In an eighth example, the sole according to example 7, wherein the distance between the tangential plane and each of the low points varies across the sole from a medial to lateral side.
(168) In a ninth example, the sole according to one of examples 2-8, wherein the section of each reinforcing member with the non-linear shape extends at least from the midfoot area to the toe area of the sole.
(169) In a tenth example, the sole according to one of examples 1-9, wherein the reinforcing members extend rearwardly beyond the midfoot area and into a heel area of the sole.
(170) In an eleventh example, the sole according to one of examples 1-10, wherein the reinforcing members are plate-like members.
(171) In a twelfth example, the sole according to one of examples 1-10, wherein the reinforcing members are rod-shaped and/or tube-shaped members.
(172) In a thirteenth example, the sole according to example 11 or 12, wherein the reinforcing members comprise solid sections.
(173) In a fourteenth example, the sole according to one of examples 11-13, wherein the reinforcing members comprise hollow sections.
(174) In a fifteenth example, the sole according to one of examples 11-14, wherein a diameter of the reinforcing members varies between at least two of the reinforcing members and/or wherein a diameter of at least one of the reinforcing members varies along said reinforcing member.
(175) In a sixteenth example, the sole according to one of examples 11-15, wherein there are five reinforcing members, each corresponding to a respective metatarsal bone.
(176) In a seventeenth example, the sole according to example 16, wherein the reinforcing members corresponding to the first and the third metatarsal bone have a higher deflection stiffness than the three remaining reinforcing members.
(177) In an eighteenth example, the sole according to one of examples 16-17, wherein the reinforcing members corresponding to the first and the third metatarsal bone have a larger diameter than the three remaining reinforcing members.
(178) In a nineteenth example, the sole according to one of examples 1-18, wherein the reinforcing members comprise one or more of the following materials: carbon fibers, a carbon fiber composite material, a glass fiber composite material.
(179) In a twentieth example, the sole according to one of examples 1-19, wherein at least two of the reinforcing members are connected by a connecting member.
(180) In a twenty-first example, the sole according to one of examples 1-20, wherein the reinforcing members extend substantially along a longitudinal direction of the sole.
(181) In a twenty-second example, the sole according to one of examples 1-21, wherein the reinforcing members are arranged next to each other in a medial-to-lateral direction.
(182) In a twenty-third example, the sole according to example 22, wherein the reinforcing members are connected to a mesh-like material.
(183) In a twenty-fourth example, the sole according to one of examples 1-23, further comprising a load distribution member arranged in a back half of the sole, preferably in the heel area of the sole.
(184) In a twenty-fifth example, the sole according to example 24, wherein the load distribution member comprises a load distribution plate.
(185) In a twenty-sixth example, the sole according to one of examples 24-25, wherein the load distribution member comprises one or more of the following materials: carbon fibers, a carbon fiber composite material, a glass fiber composite material.
(186) In a twenty-seventh example, the sole according to one of examples 24-26, wherein the load distribution member extends into the midfoot area of the sole.
(187) In a twenty-eighth example, the sole according to one of examples 24-27, wherein the reinforcing members and the load distribution member at least partially overlap.
(188) In a twenty-ninth example, the sole according to one of examples 24-28, wherein the reinforcing members and the load distribution member are independent elements.
(189) In a thirtieth example, the sole according to one of examples 1-29, wherein the reinforcing members are at least partially embedded within a midsole of the sole, and wherein the midsole comprises a plastic foam material.
(190) In a thirty-first example, the sole according to example 30, wherein the reinforcing members are completely embedded within the midsole.
(191) In a thirty-second example, the sole according to one of examples 30-31, wherein the midsole comprises a particle foam, in particular a particle foam comprising particles of expanded thermoplastic polyurethane, eTPU, particles of expanded polyamide, ePA, particles of expanded polyether-block-amide, ePEBA, and/or particles of expanded thermoplastic polyester ether elastomer, eTPEE.
(192) In a thirty-third example, the sole according to one of examples 30-32, wherein the midsole comprises a homogeneous foam material.
(193) In a thirty-fourth example, the sole according to one of examples 30-33, wherein the midsole comprises a lower midsole part and an upper midsole part, and wherein the reinforcing members are positioned between the lower midsole part and the upper midsole part.
(194) In a thirty-fifth example, the sole according to example 34 in combination with one of examples 24-29, wherein the reinforcing members and the load distribution member are separated by the upper midsole part.
(195) In a thirty-sixth example, the sole according to example 35, wherein the load distribution member is at least partially embedded within the upper midsole part.
(196) In a thirty-seventh example, the sole according to one of examples 1-36, further comprising a sock-liner.
(197) In a thirty-eighth example, the sole according to example 37 in combination with one of examples 35-36, wherein the sock-liner is arranged on top of the upper midsole part and at least partially covers the load distribution member.
(198) In a thirty-ninth example, the sole according to one of examples 1-38, further comprising an outsole.
(199) In a fortieth example, a shoe, in particular running shoe, comprising a sole according to one of the preceding examples 1-39.